【正文】 ill detect a potential Cause of failure or subsequent Failure Mode 7 Low Low chance the Design Control will detect a potential Cause of failure or subsequent Failure Mode 6 Moderate Moderate chance the Design Control will detect a potential Cause of failure or subsequent Failure Mode 5 Moderately High Moderately high chance the Design Control will detect a potential Cause of failure or subsequent Failure Mode 4 High High chance the Design Control will detect a potential Cause of failure or subsequent Failure Mode 3 Very High Very high chance the Design Control will detect a potential Cause of failure or subsequent Failure Mode 2 Almost Certain Design Control will almost certainly detect a potential Cause of failure or subsequent Failure Mode 1 DFMEA探測度判定準(zhǔn)則 PFMEA PFMEA面向的用戶 用戶包括： ? 最終用戶 ? 下一級(jí)制造或工藝 ? 工藝工程師 ? 裝配工程師 ? 維修工程師 ? 測試工程師 ? 產(chǎn)品分析 采用 PFMEA的好處 ? 是一種系統(tǒng)的方法 ? 確定與工藝相關(guān)的潛在失效模式 ? 確定潛在失效的工藝起因 ? 確定失效對(duì)用戶的潛在影響 ? 將失效模式根據(jù)其影響程度分級(jí)，優(yōu)先采取預(yù)防措施 PFMEA應(yīng)注意的問題 ? PFMEA是一個(gè)動(dòng)態(tài)文件 ? 當(dāng)產(chǎn)品的制造工藝發(fā)生變化時(shí)需要對(duì) PFMEA進(jìn)行更新 ? PFMEA從工藝流程的最前端 (接收 )開始，直到產(chǎn)品的制造過程結(jié)束 ? 制造或裝配過程的潛在失效模式 /機(jī)理都應(yīng)包含在PFMEA中，但一些信息 (如進(jìn)行嚴(yán)重度和影響分析 )可以來自 DFMEA PFMEA－ 創(chuàng)建工藝流程 ? 明確任務(wù) ? 熟悉工藝 ? 確定起點(diǎn)和終點(diǎn) ? 確定將涉及的復(fù)雜度 ? 尋找可改進(jìn)的環(huán)節(jié) 工藝是否標(biāo)準(zhǔn)化？或不同的人是否產(chǎn)生不同的效果？ 是否這些步驟經(jīng)常出現(xiàn)錯(cuò)誤？ ? 確定步驟順序 ? 描繪工藝流程 ? 分析 各工藝步驟對(duì)結(jié)果的影響 現(xiàn)有的工藝與期望的狀態(tài)有什么不同？ bad 工藝流程 開始 接收原材料 接收部件 檢驗(yàn) 檢驗(yàn) 待處理 移交生產(chǎn)部 移交生產(chǎn)部 材料加工 檢驗(yàn) 裝配 功能測試 待處理 封裝 運(yùn)輸 bad bad ok 待處理 bad ok ok ok 接收部門 制造部門 PFMEA的基本內(nèi)容 項(xiàng)目 －功能 潛在失效模式 潛在失效影響 嚴(yán)重度 S 潛在失效原因 /機(jī)理 頻度 O 現(xiàn)行設(shè)計(jì)控制 探測度 D R P N 建議措施 責(zé)任及目標(biāo)完成日期 嚴(yán)重度 S 頻度O 探測度 D R P N 來自經(jīng)驗(yàn)和數(shù)據(jù) 來自推測 重在描述 顧客抱怨 保證和維修信息 以往工作歷史 FMEA小組經(jīng)驗(yàn) (頭腦風(fēng)暴 ) Effect Criteria: Severity of Effect for PFMEA Rank Hazardous – no warning May endanger machine operator or assembly operator. Failure affects safe product operation or nonpliance with government regulation. Failure will occur without warning. 10 Hazardous – with warning May endanger machine operator or assembly operator. Failure affects safe product operation or nonpliance with government regulation. Failure will occur with warning. 9 Very High Major disruption to production line. 100% of product may have to be scrapped. The product is inoperable with loss of primary Function. 8 High Minor disruption to production line. Product may have to be sorted and a portion scrapped. The product is operable, but at a reduced level of performance. 7 Moderate Minor disruption to production line. A portion of the product may have to be scrapped (no sorting). Product is operable, but some fort / convenience item(s) are inoperable 6 PFMEA嚴(yán)重度判定準(zhǔn)則 Effect Criteria: Severity of Effect for PFMEA Rank Low Minor disruption to production line. 100% of the product may have to be reworked. Product is operable, but some fort / convenience items operate at a reduced level of performance. 5 Very Low Minor disruption to production line. Product may have to be sorted and a portion reworked. Fit finish or squeak rattle item does not conform. Most Customers notice the defect. 4 Minor Minor disruption to production line. A portion of the product may have to be reworked online but outofstation. Fit finish or squeak rattle item does not conform. Average customers notice the defect. 3 Very Minor Minor disruption to production line. A portion of the product may have to be reworked online but instation. Fit finish or squeak rattle item does not conform. Discriminating customers notice the defect. 2 None The Failure Mode has no Effect. 1 PFMEA嚴(yán)重度判定準(zhǔn)則 Probability of Failure Failure Rates Cpk Rank Very High: Failure is almost inevitable 1 in 2 10 1 in 3 9 High: Generally associated with processes similar to previous processes that have often failed 1 in 8 8 1 in 20 7 Moderate: Generally associated with processes similar to pervious processes which have experienced occasional failures, but not in major proportions 1 in 80 6 1 in 400 5 1 in 2023 4 Low: Isolated failures associated with similar processes 1 in 15,000 3 Very Low: Only isolated failures associated with almost identical processes 1 in 150,000 2 Remote: Failure is unlikely. No failures